Method to process coextruded meat products using high velocity air in combination with handling method and liquid application

Abstract

A system and method for processing a coextruded meat product including a casing enclosing a meat batter after brining in which a heated, high velocity air stream is applied to the coextruded meat product thereby mechanically removing moisture from a surface of the casing and cooking the coextruded meat product. This system and method can further improve the ability for a liquid coating to be added to the coextruded meat product in a non-drenching manner because of the superior surface preparation of the casing by the jets.

What is claimed is: 
     
       1. A method of processing a plurality of coextruded meat products each including a casing enclosing a meat batter after brining, the method comprising:
 receiving the coextruded meat products in a plurality of slots in a thermal wheel in which each of the slots receiving the coextruded meat products receives multiple ones of the coextruded meat products therein and the slots each have at least one opening formed therein to accommodate a flow of air through the slots; 
 rotating the thermal wheel to move the coextruded meat products in the slots past at least one high velocity air jet; and 
 applying a heated, high velocity air stream to the coextruded meat products, thereby mechanically removing moisture from a surface of the casing, cooking the coextruded meat products, and effectuating at least one of a lifting and a rotation of the coextruded meat products within the slots; 
 wherein, after initially being applied to the coextruded meat products and flowing through the at least one opening in one of the slots, the heated, high velocity air stream contacts a reflecting surface and is re-directed back towards the coextruded meat products. 
 
     
     
       2. The method of  claim 1 , further comprising the step of applying a liquid coating to the surface of the casing of the coextruded meat products after the step of applying the heated, high velocity air stream to the coextruded meat products. 
     
     
       3. The method of  claim 2 , wherein the liquid coating is liquid smoke. 
     
     
       4. The method of  claim 2 , wherein the step of applying the liquid coating to the surface of the casing of the coextruded meat products is performed by spraying the liquid coating onto the surface. 
     
     
       5. The method of  claim 4 , wherein the step of applying the liquid coating of the coextruded meat products involves using an ink jet technology to spray on the liquid coating. 
     
     
       6. The method of  claim 2 , further comprising another step of applying a heated, high velocity air stream to the coextruded meat products after the step of applying the liquid coating to the surface of the casing of the coextruded meat products. 
     
     
       7. The method of  claim 6 , wherein the step of steps of applying the heated, high velocity air stream to the coextruded meat products and the step of applying the liquid coating of the coextruded meat products are in a range of 8 to 10 minutes. 
     
     
       8. The method of  claim 1 , wherein the step of applying the heated, high velocity air stream to the coextruded meat products involves varying at least one of the temperature, velocity, and humidity of the air stream over a duration of the step. 
     
     
       9. The method of  claim 1 , wherein the air being applied to the coextruded meat products at the step of applying the heated, high velocity air stream to the coextruded meat products is not controlled prior to application to remove moisture therefrom. 
     
     
       10. The method of  claim 1 , wherein the step of applying a heated, high velocity air stream to the coextruded meat products cooks and conditions the coextruded meat products. 
     
     
       11. The method of  claim 1 , further comprising, before the step of applying the high velocity air to the coextruded meat products:
 coextruding a meat batter into a casing to form a sausage rope; 
 brining the sausage rope to coagulate the casing; and 
 crimping and cutting the sausage rope to form the coextruded meat products. 
 
     
     
       12. The method of  claim 1 , wherein the air velocity of the heated, high velocity air stream is up to 3000 meters per minute air velocity per jet. 
     
     
       13. The method of  claim 1 , wherein the heated, high velocity air increases a core temperature of the coextruded meat products in a range of 4° C. to 24° C. to a temperature in a range of 40° C. to 60° C. 
     
     
       14. The method of  claim 1 , wherein the coextruded meat products are subjected to between five and twenty separate treatment cells. 
     
     
       15. The method of  claim 14 , wherein each treatment cell provides between 15 to 170 air changes per minute. 
     
     
       16. A system for processing a plurality of coextruded meat products each including a casing enclosing a meat batter after brining, the system comprising:
 a thermal system adapted to convey the coextruded meat products therethrough, the thermal system including at least one high velocity air jet for applying a heated, high velocity air stream to the coextruded meat products in an amount capable of mechanically removing moisture from a surface of the casing and cooking the coextruded meat products; 
 wherein the thermal system further includes a thermal wheel comprising a plurality of slots in which each of the slots is configured to receive multiple ones of the coextruded meat products therein, with the slots each having at least one opening formed therein to accommodate a flow of air through the slots; and 
 wherein the thermal wheel is rotatable to move the slots past at least one high velocity air jet, the at least one high velocity air jet applies the heated, high velocity air stream to the coextruded meat products to mechanically remove moisture from a surface of the casing, cook the coextruded meat products, and effectuate the rotation of the coextruded meat products within the slot and is further configured such that, after initially being applied to the coextruded meat products and flowing through the at least one opening in one of the slots, the heated, high velocity air stream contacts a reflecting surface and is re-directed back towards the coextruded meat products. 
 
     
     
       17. The system of  claim 16 , wherein the system further comprises a second thermal wheel comprising another plurality of slots configured to receive the coextruded meat products therein in which the second thermal wheel is rotatable to move the other slots past at least another one of the at least one high velocity air jets and wherein the system further comprises an applicator that is disposed between the first thermal wheel and the second thermal wheel and is adapted to apply a liquid coating to the surface of the casing of the coextruded meat products. 
     
     
       18. The system of  claim 17 , wherein the liquid coating is liquid smoke. 
     
     
       19. The system of  claim 17 , wherein the system transports a given coextruded meat products through the thermal wheel, the applicator, and the other thermal wheel in a time range of between 8 and 10 minutes. 
     
     
       20. The system of  claim 17 , wherein the applicator utilizes ink jet technology in order to apply the liquid coating. 
     
     
       21. The system of  claim 16 , wherein the at least one high velocity air jet includes a plurality of high velocity air jets and the plurality of high velocity air jets are spaced apart from one another around at least a portion of the circumference of the thermal wheel. 
     
     
       22. The system of  claim 21 , where the plurality of high velocity air jets are configured to provide respective heated, high velocity air streams at least some of which have at least one of different velocities, different temperatures, and different humidities from one another, thereby defining a plurality of treatment cells around the circumference of the thermal wheel. 
     
     
       23. The system of  claim 16 , wherein the at least one high velocity air jet is configured to provide a variable amount of at least one of velocity, temperature, and humidity in order to vary an air stream emitted from the at least one high velocity air jet over a duration of time. 
     
     
       24. The system of  claim 16 , wherein the system does not remove moisture from a source of air prior to using the source of air in the heated, high velocity air stream from the at least one high velocity air jet. 
     
     
       25. The system of  claim 16 , the system further comprising a coextruder, a briner, and a crimper and/or cutter mechanism configured to prepare the coextruded meat products prior to processing the coextruded meat products in the thermal system. 
     
     
       26. The system of  claim 16 , wherein the air velocity of the heated, high velocity air stream from the at least one high velocity air jet is up to 3000 meters per minute air velocity per jet. 
     
     
       27. The system of  claim 16 , wherein the heated, high velocity air from the at least one high velocity air jet increases a core temperature of the coextruded meat products in a range of 4° C. to 24° C. to a temperature in a range of 40° C. to 60° C. 
     
     
       28. The system of  claim 16 , wherein the system provides between five and twenty separate treatment cells. 
     
     
       29. The system of  claim 28 , wherein each treatment cell is capable of providing between 15 to 170 air changes per minute. 
     
     
       30. The method of  claim 1 , wherein the slots carrying the coextruded meat products are arranged circumferentially around the thermal wheel and are angularly offset from one another such that they form a series of infinitely parallel rows as the thermal wheel rotates. 
     
     
       31. The system of  claim 16 , wherein the slots configured to carry the coextruded meat products are arranged circumferentially around the thermal wheel and are angularly offset from one another such that they form a series of infinitely parallel rows as the thermal wheel rotates. 
     
     
       32. The method of  claim 1 , wherein in each of the slots receiving the coextruded meat products, the coextruded meat products are arranged in a single linear row within the respective slot. 
     
     
       33. The system of  claim 16 , wherein in each of the slots receiving the coextruded meat products, the coextruded meat products are arranged in a single linear row within the respective slot. 
     
     
       34. The method of  claim 1 , wherein after the heated, high velocity air stream contacts the reflecting surface and is re-directed back towards the coextruded meat products, the heated, high velocity air stream further contacts another reflecting surface to further re-direct the heated, high velocity air stream and produce a serpentine flow path for the heated, high velocity air stream. 
     
     
       35. The system of  claim 16 , wherein after the heated, high velocity air stream contacts the reflecting surface and is re-directed back towards the coextruded meat products, the heated, high velocity air stream further contacts another reflecting surface to further re-direct the heated, high velocity air stream and produce a serpentine flow path for the heated, high velocity air stream.